Laminated roofing or sheet product



May 19, 1936. c. BATCHELLER LAMINATED ROOFING 0R SHEET PRODUCT Filed De.23, 1933 Patented May 19, 1,9361 A. i

Ultrr-Ezn;srnrrss' PATENT 'y olfFl-cs My invention relates to rigid orsemi-rigid roofing and sheathing products, and to the method yof' makingthesame.'` It relates particularly to articles of this' character`composed primarily of hydraulic cement andfflbrous material `andcomprising two or m`ore laminae having' different characteristics, suchas color, which are iconcreted together to form a unitary structure.

It has heretofore been proposed,` to effect a decorative` coloration orcementfflber products of the character described by incorporating acolor pigment with "the materials of which the base is made. In this waya` solid colored product is obtained. Due to the comparatively largeamount of pigment required to color 'the entire product/and to therelatively' high' cost of some` of the/pigments, such as green chromeoxide, which might otherwise be employed, products of this characterare,` for the most part, limited to those in which the color effect isobtained by the common iron oxide colors andochres;

Color effects are 'also produced by a-veneering process which consistsin applying 'a water solution of neatcement and pigment directly to theface of the product while itl is still plastic and bonding it to thebody by pressure. SuchI a color veneer is only about three-thousandths`of an inch thick, it cannot be bonded perfectly to a. cement-*fiberbase, and hence, its life upon ex' posure to theelements is short. f r.v

Colored products produced by pressing particles of colored slate and thelike directly into the surface of alcement-ilber base are unsatisfactory because of their high porosity and consequent moisturepermeability. f The principal object of my invention is to produce aroofing or sheathing product of the rigid or semi-rigid type having abody comprising hy-A draulic cement and brous material. and pro-` videdwith a.A colored surfaceV or layer bonded to and concreted with the bodyof 'the product to form a unitary structure substantially impervij ineach figure represents asphalt;

l,in which asphalt is placed between the laminae before they areconcreted together; o Flg. 5 is a fragmentary enlarged cross sectlonshowing color granules concreted to a base cc taining asphalt; and

l 5 Fig. 6 is a fragmentaryv enlarged cross section Ashowing a thincolor llayer comprisingY nea't cement and pigment concreted to a baseelement containing asphalt.

. The objects of my invention are attained by 10 'the useof asphalt orpreferably asphalt emul.-

sion in the manner hereinafter set forth.

I may, for example, incorporate smallpproportions (preferably less than'about 5% by weight) of asphalt emulsion inV theplastic mixture'of 1'5hydraulic cement and brous )material going Vto make up the body I of theproduct as. shown inA Fig. 6. ',I'o this body, while in the plasticstate,

a surface layer 2 of neat hydraulic cement and; pigment may be bondedand the two concreted 2o together by subjecting the product tosubstantial pressure. This pressure will extru`de some of the asphaltfrom the body of the product and bring it to the surface where it servesnot only to seal. the body of,the product andrender it 25 impervious tomoisture butalso to seal and bond the color layer to the body. Y

A much thicker layer of color and one which isv more firmly bonded tothebody of the product can be produced by adding a smallpropor- 30A tion ofasphalt emulsion to the colored plastic 3, as shown in Fig. 1, orpreferably to both the lcolor plastic 3 and the body plastic I, as shownin Fig. 3, it being understood that the stippl'lng Y V l Only very 35small percentages of .asphalt emulsion arenecessary to obtain perfectbondingv and a moisture impervious product; but percentages upto thosewhich do not detrimentally affect the coloration.

may obviously be employed. Forl example, the 40 bonding of a color layerto the body of the product and the impermeabilityV of the compositestructure is greatly improved by-additions of asphalt emulsion to thecolor plastic in amounts as small as from 1/ to 1% by weight.small`amounts of 'asphalt do not diminish the -brilliancy of the color,and-the surface texture of the product is decidedly improved thereby. f

Instead of using asphalt incorporated eitherv in the body of theproduct, as shown in Fig. 2, 50 or inthe color layer, as shownin Fig. 1,or in both,

it is still wet and plastic. 'I'his application may 55 Such 45- '2` v Yr. -beeituennupnnimnninonorsmugntuphnit to ai condition of suitableiiuidity by heat Dlrectlyuponthissingleor'doubleiiimofasphaltlmayapplyaheavypiastic coating of t color combinedwith neat cement andwater,or, Imayformthe colorlayeras aiseparate'laminaand thereafter apply it'to the The structure is` then thor- -:oughlybonded and concreted together, while plastic, by the application ofpressure Whereonly a thin or veneer ofcolor is"v Idesired,lmayin'steadofapplylngaheavy hier.

oli-'colored plastic, spray a nlm of neat cement `and' pigment, eitherwith or without an asphalt" emulsion, over the asphalt covered surfaceand bondtbe whole together by pressure.

'colored granules I my beused inirteiuioi:

i pigments to obtain the desired color enoctand the maybe applieddirectly to the asphalt coated base and bonded therewith by theapplication of Where an asphalt emulsionis incorporated inthecement-fiber base, color nodules orgranuie's may be bonded directlythereto Iwithout spraying the basewith asphalt and withoutincorporatingv an asphaltic emulsion with the color granules, althoughit is to be understood that the latter' maybe done if desired.)

In any vme the asphalt, whether usedras, an

emulsion or sprayed or otherwise applied directly Vto the surface of thecement-fiber base, serves perfectlytobondthecolorlayertothebodyof theproduct when substantial/pressure is applied and thewhole is in'plasticc" dition'. In the one casethensphaltisalready/ weenthelayers to beboundtogetner and in meother casema brought thereby pregare. The asphaltserves eifectually to seai'the product against the en-f trance ofmoisture and thus eil'ectually io'prevent eilio'. Y l

While the products described `above maybe `manufacturedbytheuse ofanytnowusedinthe'art,lprefertousetli'e machine disclosed in myapplicationSerial No. 553,818. f

While I 'have described .my invention in its.

preferred,itistobeunderstoodthat the words which Ihave used are words ofdescription and not of limitation. Hence, changes within the purview ofthe appended claims may .be made without departing from the true scopeand spirit of my invention in its broader aspects.

What I claim is: I "-1. Alaminatedrooiingorsheathing product of thecharacter described comprising a containing fibrous material andhydraulic cement,

and a surface lamina containing hydraulic ce' ment and-a coloringsubstance; said lamina beingconcreted together to form a unitarystructure, and thefsone including the adjacent portions ofsaidlaminaecontainingaminorquantityof 2. A laminated rooiingor sheathing product ofthe-character described a base lamina containing nbrous material fand-hydraulic -cement, asurface lamina containing hydraulic cef-' ment anda coloring substance, and a sone containing portionsof boni saidlainimemd iy A minor quantity of asphalt.

3. A laminated rooiingor sheathing productof the characterV described'comprising a plurality `of ihminae having din'erent characteristicsconcreted together but each containing hydraulic cementandasmallquanidtyofanasphaltinitiallymiscihie with water. I

4. Themethod ofnnking'a rooting` .or lsheathing product of the characterdescribed "which comprises forming a ibase lamina of a i plasticcontaining 'iibrous material and hydraulic cement, applying afthin layeror coating of liquid asphalt to a smfacethcrcof while plastic, forming asurface lamina of a plasticcontainin'g-coloring pigment and hydrauliccement, .superposing the surface lamina on the asphalt covered surfaceof the base laminafand'compacting and concreting the lainina'e` togetherwhile plastic by the application of 15. The method .of making alaminated roofing or sheathing product' ofthe character described whichcomprises forming a'base lamina` of a plastic containingiibrous'material, hydraulic cement and a small proportion of asphaltemulsion, ap-

' plying a thin layeror coating of liquid asphalt to a surface thereofwhile plastic, forming a surface lamina of -plastic containing coloringpigment and hydraulic' cement', superposing the surface lamina on theluiseiaxx'iina,` andfcompacting and concretingy the together,v whileplastic, by the application 'of substantial pressure.

6. 'l'be method of making a laminated-rooting or sheathing product ofthe character .described which comprises forming a base lamina of aplastic containing fibrousmaterial and hydraulic cement, applyinga thinlayer or coatingof liquid asphalt to a surface thereof while plastic,forming a surface lamina` of a plastic containing color.-

ing pigment, a small quantity of asphalt emul sion, and hydrauliccement, superposing the surface lamina on the asphalt covered surface ofthe base lamina, and compacting and ccncreting the laminae togetherwhile plastic by the application of substantial pressure.v

7. The methodot making a laminated roonng which comprises forming abase'lamina of a plastic containing fibrous material, hydraulic cementand a small proportion of asphalt emulsion, applying a vthin layer or'coating of liquid asphalt to a surface thereof while plastic, forming asur- .face lamina of plastic containing coloring pigment, a smallquantity of asphalt emulsion, and hydraulic cement, the surface-laminaon the base lamina, and compacting and concret' ing the iaminaevtogether, while plastic, by thel application of substantial pressure. 1

8. The methodof making a colorsurfaced roofing or'sheathing product ofthe character deapplication of substantial pressure.

f 9. A roofing or sheathing product of therigid cementitious typecomprising a plurality oflayers for laminae ofthe same general characterbut having'soinewhatl diil'erent characteristics, such as zcolor,iconcreted'together-with a minor quantity of asphalt to form a denseunitary structure:

i at least one of ysaid laminae comprising principally fibrous materialand'hydraulic cement.

. 10. A roofing orsbeathing product of the rigid cementitious typecomprising a plurality of layers or laminae of the same generalcharacter but having somewhat different characteristics. such tity ofasphalt'to form a unitary structure; each lamina containing hydrauliccement as a principal bondingmaterial and at least one of orsheathingproduct of the character described as c olor, concreted' together with aminor quansaid laminae containing a minor quantity of asphalt.

11. A roofing or sheathing product of the rigid cementitious typecomprising a plurality of layers or laminae of the same generalcharacter but having somewhat different characteristics, such as color,concreted together with a minor quantity oi asphalt to form a denseunitary structure; one

of said -laminae containing iibrous material and at least one of saidlaminae containing a minor quantity of asphalt.

12. A roofing or sheathing product of the rigid cementitious typecomprising a plurality of layers or laminae of the same generalcharacter but having somewhat different characteristics, such as color,concreted together to form a dense unitary structure; at least one ofsaid laminae comprising principally iibrous material and hydrauliccement, and all of said layers containing a small quantity of asphalt.

13. A roong or sheathing product of the rigid. cement-asbestos typecharacterized by its resistance to efliorescence and comprising a baseportion of hydraulic cement and fibrous material, and a surface portioncontaining a coloring medium; the surface portion and the adjacentportion'ot the base being coalesced together and the zone of coalescencecontaining asphalt but in a quantity less than will substantially aiectthe color of the surface portion.

14. The method of making a dense rooiing or sheathing product of therigid, cementitious type having laminae of diierent character which com;prises separately forming said laminae from plastic ber mixturescontaining hydraulic cement, superposing said laminae and subjecting thewhole to substantial pressure while plastic with an asphalt film betweensaid laminae.

CIEMENTS BATCHEILER.

